The following article is taken from the AMA National Newsletter.
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This article is by Jack Tyson.

PROP SAFETY

If you are itching to try a scratch-built aircraft but are not sure you can do it, this article is for you. I have built five scratch-built airplanes over the past three years and have learned some simple tricks to make it more fun and easier to build.

The notion that you have to be a really good builder and know all the tricks is simply not true. There are some simple tips that can help keep you out of trouble. If you have built a few kit aircraft and can follow a blueprint, you are ready to try a scratch-building.

Try to keep your effort to something that is not too intricate. I suggest picking something that you might have seen in full-scale, staying away from military and multi-engine airplanes.

You can find many neat aircraft in any of the model magazines. There are many good designs and designers to choose from.

Make your choice, send for the blueprints. and get ready for some fun.

Since you are building without a build book, it is a good idea to take some time to study the blueprints and look for potential problems. Make a note of the areas that may need special attention. Most of the designers supply a phone number where you can call for ordering blueprints or to clarify a problem area. Some designers will have such things as engine cowling, landing gear, etc., available if you wish to purchase them.

Now that you have studied the print pretty well, it is time to make a list of needed materials. Using a yo-yo tape or yardstick, you can measure the length and width of the material you will need. I take a section at a time, such as the fuselage, listing each type by size and thickness, then measure for length. You may wind up with IO or 15 different types of material. Do the next component, such as the wing, listing these requirements. When you have done each component, take your lists and make one master list combining like materials. Now you have a bill of materials and can check your on-hand material for availability. The rest of the material can be ordered from any supplier.

Now that you have your material on order, it is a good time to think about how to cut parts. I find that it is easier for me to take my blueprint to a print shop and make copies of all contour parts. Using the II inch by 1 7 inch copier, I get copies of all ribs, wing tips, formers, and everything that requires contour cutting. Be sure to check that the first copy comes out exactly the same size as the blueprint. You should have the setting on the copier at 100%. Now you have a paper template of all contoured parts. Cut the part out of the copy with scissors and leave a 1/2 inch border around the part. Using children's glue stick, put glue on the backside of the template and stick it directly to the balsa or whatever material the print calls for. You are now ready to cut out your part. I have a scroll saw, router, drill press and table saw in my workshop. That's great if you have them, but you can still do it manually with an Hobby knife and keyhole saw. Cut each part accurately and sand the edges lightly. You are ready to build!

Assembly is the same as a kit build since, in effect, you have made your own kit. All throws for controls are shown on the print and some building instructions are available in the model magazines. Each month they feature art aircraft and have instructions and prints for you to purchase.

It is really not that difficult and is a lot of fun. It gives you the chance to have an aircraft that no one else in your club may have. As to covering and details such as seating, instrument panel, etc., you are limited only by your own imagination. So scratch that itch and get going on your own scratch built.

from Balsa Chips
140 Edna Ave.
Bridgeport CT 06610-1732